Multi-objective Optimization of Combined Internal Components with a Vortex Stabilizer and Apex Cone for Performance Improvement of Cyclone Separator

Multi-objective optimization of a cyclone with combined internal components, including a vortex stabilizer and apex cone, was studied for performance improvement. Response Surface Methodology (RSM) and Computational Particle Fluid Dynamics (CPFD) were employed to investigate the effects of four parameters: vortex stabilizer diameter DH, apex cone bottom length DS, position BS, and height BH on separation efficiency, pressure drop, and quality factor. The desirability function was used to determine the optimized structure. The results demonstrated that DS primarily affected separation efficiency and quality factor, whereas DH mainly influenced pressure drop. The reduction in these two parameters, as well as the decrease in BS, contributed to performance enhancement relative to their original values. After optimizing, separation efficiency, pressure drop, and quality factor could be improved by 5.605 %, 0.910 % and 16.673 %, respectively, and DH, DS, BS and BH were recommended at 27.512, 115.354, −80.1099 and 109.317 mm, respectively. In contrast to the original cyclone, the optimized separator exhibited a more stable flow due to the lower vortex end and minor wall turbulent viscosity. Although static pressure increased, particle back-mixing was alleviated. Additionally, the extended particle flow descending distances and the enlarged effective passage area enhanced particle centrifugal force and decreased particle volume fraction, respectively, thereby improving separation efficiency. Finally, the optimized separator exhibited enhanced overall performance across various operating parameters.